CN104144895A - A method of forming a gypsum based product - Google Patents
A method of forming a gypsum based product Download PDFInfo
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- CN104144895A CN104144895A CN201280069286.8A CN201280069286A CN104144895A CN 104144895 A CN104144895 A CN 104144895A CN 201280069286 A CN201280069286 A CN 201280069286A CN 104144895 A CN104144895 A CN 104144895A
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- slurry
- alpha
- water
- gypsum
- hemihydrate
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F11/00—Compounds of calcium, strontium, or barium
- C01F11/46—Sulfates
- C01F11/466—Conversion of one form of calcium sulfate to another
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
- C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
- C04B28/146—Calcium sulfate hemi-hydrate with a specific crystal form alpha-hemihydrate
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B11/00—Calcium sulfate cements
- C04B11/02—Methods and apparatus for dehydrating gypsum
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B11/00—Calcium sulfate cements
- C04B11/02—Methods and apparatus for dehydrating gypsum
- C04B11/028—Devices therefor characterised by the type of calcining devices used therefor or by the type of hemihydrate obtained
- C04B11/032—Devices therefor characterised by the type of calcining devices used therefor or by the type of hemihydrate obtained for the wet process, e.g. dehydrating in solution or under saturated vapour conditions, i.e. to obtain alpha-hemihydrate
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/10—Accelerators; Activators
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
- C04B2111/0062—Gypsum-paper board like materials
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Inorganic Chemistry (AREA)
- Crystallography & Structural Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
A method of forming a gypsum based product is disclosed. The method comprises the steps of: calcining a mixture of water and gypsum under conditions of raised temperature and pressure within a vessel to produce an alpha-hemihydrate slurry therein; passing the alpha-hemihydrate slurry from the vessel to a mixer for mixing with additional water to produce a settable slurry, which is arranged to set to form the gypsum based product.
Description
The present invention relates to form the method for the product based on gypsum.
Gypsum exists natively as the raw material of calcium sulfate dihydrate form.Wrap gypseous product, plasterboard (plaster board for example, plasterboard), by being prepared as follows: forming through gypsum calcining or through dewatering is the mixture of calcium sulfate hemihydrate and water, to form the slurry that can condense, then the described slurry that can condense is cast into predetermined shape.Described semihydrate reacts with water and the rehydrated dihydrochloride dihydrate crystal that becomes that becomes, and then described dihydrochloride dihydrate crystal solidifies or be dried to solid state.
The hemihydrate form of known gypsum depends on calcination process, and is categorized as two kinds of basic forms: alpha-hemihydrate and β-semihydrate.β-semihydrate typically forms by following: gypsum is heated under atmospheric condition, and to drive away any moisture and chemically combined water to form the crystal of drying, then the crystal of described drying can be ground into thin powder.Due to rehydrated rapidly when forming slurry of the crystal through grinding, in the manufacture of gypsum wallboard or plasterboard, β-semihydrate is the semihydrate of being had a preference for for a long time.Yet the gypsum product that derives from β-semihydrate typically soft and β-hydrate needs the water of large volume to produce required slurry fluidity.
Alpha-hemihydrate forms by following: gypsum is heated under pressure to remove similarly the water with its combination.Yet, find to compare with the gypsum that derives from β-semihydrate the gypsum product that derives from alpha-hemihydrate harder and comprise higher intensity and density.
Must in gypsum slurry, use the water of significant quantity to guarantee the suitable mobility of slurry.Unfortunately, the major part of this water must finally be driven away by heating, and due to the high cost of the fuel using in heat-processed, this is expensive.Heating steps is also consuming time.Known alpha-hemihydrate has than the remarkable low water demand of β-semihydrate, means that, if alpha-hemihydrate can be used when manufacturing wallboard, it will significantly reduce water demand and therefore reduce and manufacture required expense and the time of wallboard.This is the further advantage relevant with alpha-hemihydrate.
Yet in the production of gypsum wallboard, alpha-hemihydrate is not commercially generally used, this is mainly because it compares lower hydration rate with β-semihydrate, and therefore this will require plate along slower the passing through of production line.
WO2007/084346 discloses the production method of α-type gypsum.Gypsum slurry is delivered in autoclave, in autoclave, gypsum slurry is typically heated to the temperature of approximately 280 °F (approximately 137 ℃) and changes into alpha-hemihydrate under the pressure of 3-4 bar.Described slurry leaves autoclave and is delivered to flash tank via pressure decreased valve, in flash tank, it is cooling and collect excessive steam.
US2008/0069762 discloses the method for the manufacture of the blend of α-plaster (stucco) and β-plaster.Described method comprises and for example wherein gypsum slurry is remained in reactor to the temperature of 149 ℃ and for example slurry calcining step of the pressure of 3.4-4.8 bar.Storage tank is discharged and be fed to gypsum product through part calcining as the slurry that comprises calcium sulfate dihydrate and alpha-calcium sulphate semihydrate from reactor, and it serves as collector (holding tank) permission at the pressure drop of slurry released vapour during to barometric point.Dewatering unit is discharged and be fed to slurry then from storage tank, and described dewatering unit produces through the product that contains solids of dehydration and the water logistics being removed except anhydrating.Product through dehydration has 2-6 % by weight free water moisture content.Product through dehydration is fed in making the most of of gypsum in the product of dehydration or all changing into the plate plaster can-type calcine furnace of the condition of β calcium sulfate hemihydrate.
According to the present invention who sees from first aspect, the method that forms the product based on gypsum is provided, described method comprises the steps:
The mixture of water and gypsum is calcined to produce therein alpha-hemihydrate slurry in container under the condition of the temperature and pressure raising;
Described alpha-hemihydrate slurry is passed to mixing tank from described container and for the water with other, mix to produce the slurry that can condense, the described slurry that can condense is arranged to condense to form the described product based on gypsum.
Advantageously, described method is eliminated and is formed the relevant dry needs for semihydrate with the routine of the slurry that can condense, and therefore reduces the energy requirement amount of described method.And the water yield of comparing the minimizing relevant with the mobility of expectation that realizes the slurry that alpha-hemihydrate can condense with β-semihydrate provides further energy saving, because the water that must remove between the dry epoch of gypsum product still less.
Preferably, described calcining step comprises that water and gypsum fill described container fully, so that the essentially no freeboard of described container, makes to prevent the water evaporation producing during the calcining of gypsum.
Preferably, the temperature of described rising is included in 110 ℃-170 ℃, preferably 120 ℃-150 ℃, the more preferably temperature within the scope of 130 ℃-140 ℃.
Typically, according to service temperature, regulate pressure, make working pressure corresponding to the vapour pressure of the steam under described service temperature.Preferably, the pressure of described rising is included in 2-8 bar, the more preferably pressure within the scope of 3-5 bar.
Described method preferably further comprises the step of cooling described alpha-hemihydrate slurry after described calcining step.Typically, the step of cooling described alpha-hemihydrate slurry occurs when making described alpha-hemihydrate slurry still be maintained at about the pressure of rising of 2-8 bar.Typically, the step of cooling described alpha-hemihydrate slurry is used heat exchanger to implement.Preferably, described alpha-hemihydrate is cooled to lower than 100 ℃, for example the temperature of 90 ℃.
Preferably, after the step of cooling described alpha-hemihydrate slurry, make described slurry be decompressed to the pressure of 1 bar (being barometric point).
Typically, described method be further included in reducing effect after the step of the pressure of described alpha-hemihydrate slurry by water with (from) described alpha-hemihydrate slurry separated step fully.This can for example use belt filter or centrifuge separator is that hydrocyclone carries out.Preferably, in this case, by separated water cycle for the mixture with the gypsum of fresh amounts, thereby to be incorporated into, in described container, start further calcination process.In this case, being included in heat energy in separated water reduces for the described container of heating for example to realize the demand of temperature of the rising of 110 ℃-180 ℃.
By water with (from) the situation of described alpha-hemihydrate pulp separation, the free water content of remaining slurry typically is 1-30 % by weight, preferably 5-30 % by weight, more preferably 8-30 % by weight.
Preferably, described method further comprises that the described alpha-hemihydrate slurry of grinding is to reduce the step of the size of particle wherein.Think that the grinding of described alpha-hemihydrate slurry causes the reactivity that alpha-hemihydrate particle is larger, to improve the hydration rate of the alpha-hemihydrate particle during the step that forms the slurry that can condense.Grind the step of described alpha-hemihydrate slurry and can use wet grinding technology implementation.In this case, described grinding can 50 ℃ or higher, preferably 70 ℃ or higher, more preferably at 80 ℃ or higher temperature, implement.
For being as known in the art and can be used as the surrogate of described grinding steps or also can use described method except described grinding steps in the method for controlling the size of described alpha-hemihydrate particle during described calcination stage.
Preferably, during described alpha-hemihydrate slurry is passed to the step of described mixing tank from described calcining vessel, the temperature of described alpha-hemihydrate slurry is remained on to 70 ℃ or higher.By the temperature of described alpha-hemihydrate slurry is remained on to this level, think and can avoid described alpha-hemihydrate particle hydration to form the gypsum product that can condense, until described alpha-hemihydrate slurry enters in described mixing tank.Preferably, the temperature of described alpha-hemihydrate slurry is remained on 80 ℃ above, more preferably more than 85 ℃.
In addition, desirable, the step that described alpha-hemihydrate slurry is passed to described mixing tank from described calcining vessel should not spent the long time, with further avoid described alpha-hemihydrate particle hydration until described particle enter in described mixing tank.Typically, by described alpha-hemihydrate slurry from described calcining vessel pass to described mixing tank institute's time spent be less than 120 minutes, be preferably less than 60 minutes, more preferably less than 30 minutes.
Think, in described mixing tank, add cold water (for example approximately 20 ℃-30 ℃) for mixing the temperature of described alpha-hemihydrate slurry will promptly be reduced with described alpha-hemihydrate slurry, to promote described alpha-hemihydrate particle hydration to form the gypsum product that can condense.
Described method further comprises to the semihydrate slurry in described mixing tank adds one or more other additives, for example promotor and whipping agent.
Preferably, the described product based on gypsum comprises plasterboard.
According to the present invention who sees from second aspect, the method that forms the product based on gypsum is provided, described method comprises the steps:
The mixture of water and gypsum is calcined to produce therein alpha-hemihydrate slurry in container under the condition of the temperature and pressure raising;
Described alpha-hemihydrate slurry is passed to mixing tank from described container and for the water with other, mix to produce the slurry that can condense, the described slurry that can condense is arranged to condense to form the described product based on gypsum, and wherein said alpha-hemihydrate slurry passes to described mixing tank from described container in the situation that not experiencing drying stage.
The preferred feature of the method for described second aspect can comprise preferred feature one or more of the method for described first aspect.
Now will be only by way of example and embodiments of the present invention are described with reference to the drawings, described accompanying drawing provides the schematic diagram of the step relevant with method according to the embodiment of the present invention.
With reference to accompanying drawing, method according to the embodiment of the present invention comprises following initial step: with approximately 1 part of gypsum, the ratio of 1.5 parts of water is formed the mixture 20 of water and gypsum 10, in pressurizer 30, described mixture pressurizeed and pass through heat exchanger 40 (for example water/water heat exchanger) it is heated in advance.Then described mixture is introduced in calcining vessel 50, for example, by pump or with long water pipe (water column, water column), carried out.Subsequently described mixture is heated to the temperature within the scope of 130 ℃-140 ℃ and container 50 is forced into the pressure within the scope of 3-5 bar.With described mixture fully filling container 50 to remove any freeboard wherein, make to prevent the water evaporation of water in container 50 and the main calcining that derives from described gypsum and therefore escape container 50.
After described calcination stage, use heat exchanger 40 mixture of the water of gained and alpha-hemihydrate slurry 60 to be cooled to the temperature of approximately 90 ℃, in pressure reducer 70, reduce pressure and pass to separating unit 80, described semihydrate slurry is separated fully with water therein.Described water is circulated back to container 50 water subsequently heated in advance and therefore to reduce the energy requirement amount relevant with the heating of mixture before entering container 50 with gypsum from separating unit 80.The alpha-hemihydrate slurry that comprises approximately 6% water is passed to mixing tank 90 from separating unit 80, aftertreatment subsequently for described slurry, it comprises interpolation water 100 and optional additive, and for example promotor 110 (for reducing time of coagulation) and whipping agent 120 are to produce the slurry that can condense.Yet, also imagine described aftertreatment and can further comprise and grind described semihydrate slurry (for example, in thread grinder 140) to reduce to be arranged on the size of particle wherein before in described alpha-hemihydrate slurry is incorporated into mixing tank 90.In this, described semihydrate slurry passes to mixing tank 90 to realize required mobility and congealing property without successive what drying stage in the situation that, reduces thus the energy requirement amount when manufacturing described gypsum product.And, owing to comparing the amount of the needed water of mobility of the expectation that realizes the slurry that described alpha-hemihydrate can condense with the amount of the needed water of mobility that realizes the expectation of the slurry that β-semihydrate can condense, reduce still less curing of the slurry that can condense that comprises 30-40% water of gained (then it be transferred to production line 130 for for example preparation of plasterboard of gypsum product subsequently) needs.Because alpha-hemihydrate typically has the hydration rate slower than β-semihydrate, the time of coagulation of alpha-hemihydrate slurry is typically long than β-semihydrate slurry.Therefore, in the manufacture of plasterboard, conventionally desirable when using alpha-hemihydrate slurry, there is longer formation band and think that condensing of slurry provides the sufficient time.
Claims (17)
1. form the method for the product based on gypsum, described method comprises the steps:
The mixture of water and gypsum is calcined to produce therein alpha-hemihydrate slurry in container under the condition of the temperature and pressure raising;
Described alpha-hemihydrate slurry is passed to mixing tank from described container and for the water with other, mix to produce the slurry that can condense, the described slurry that can condense is arranged to condense to form the described product based on gypsum.
2. according to the method for claim 1, further comprise the steps: that the water-content that reduces described alpha-hemihydrate slurry is to provide the separated water logistics from described alpha-hemihydrate slurry.
3. according to the method for claim 1 or claim 2, wherein said calcining step comprises that water and gypsum fill described container fully, so that the essentially no freeboard of described container, makes to prevent the water evaporation producing during the calcining of gypsum.
4. according to the method for any one in aforementioned claim, the temperature of wherein said rising is included in the temperature within the scope of 110 ℃-170 ℃.
5. according to the method for any one in aforementioned claim, the pressure of wherein said rising is included in the pressure within the scope of 2-8 bar.
6. according to the method for any one in aforementioned claim, be further included in the step of cooling described alpha-hemihydrate slurry after the step of mixture of the described water of calcining and gypsum.
7. according to the method for claim 6, wherein described alpha-hemihydrate slurry is cooled to the temperature lower than 100 ℃.
8. according to the method for claim 6 or claim 7, be included in the further step that makes described slurry decompression after the step of cooling described alpha-hemihydrate slurry.
9. method according to Claim 8, further comprises and makes the water logistics circulation of described separation further gypsum is heated in advance before entering described container.
10. according to Claim 8 or the method for claim 9, wherein, after the step of water-content that reduces described alpha-hemihydrate slurry, the water-content of described alpha-hemihydrate slurry is positioned at the scope of 1-10 % by weight.
11. according to the method for arbitrary aforementioned claim, further comprises and grinds described alpha-hemihydrate slurry to reduce the step of the size of particle wherein.
12. according to the method for any one in aforementioned claim, and the step that wherein described alpha-hemihydrate slurry is passed to described mixing tank from described container comprises the temperature of described alpha-hemihydrate slurry is remained on to more than 70 ℃ steps.
13. according to the method for any one in aforementioned claim, wherein described alpha-hemihydrate slurry is passed to the described mixing tank time used from described container and is less than 120 minutes.
14. according to the method for arbitrary aforementioned claim, further comprises to described semihydrate slurry and adds water.
15. according to the method for claim 14, further comprises to the described semihydrate slurry in described mixing tank and adds one or more additives, for example promotor and/or whipping agent.
16. according to the method for arbitrary aforementioned claim, and the wherein said product based on gypsum comprises plasterboard.
17. form the method for the product based on gypsum, and described method comprises the steps:
The mixture of water and gypsum is calcined to produce therein alpha-hemihydrate slurry in container under the condition of the temperature and pressure raising;
Described alpha-hemihydrate slurry is passed to mixing tank from described container and for the water with other, mix to produce the slurry that can condense, the described slurry that can condense is arranged to condense to form the described product based on gypsum, and wherein said alpha-hemihydrate slurry passes to described mixing tank from described container in the situation that not experiencing drying stage.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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GB1121589.4A GB2497574B (en) | 2011-12-15 | 2011-12-15 | A method of forming a gypsum based product |
GB1121589.4 | 2011-12-15 | ||
PCT/EP2012/075353 WO2013087754A1 (en) | 2011-12-15 | 2012-12-13 | A method of forming a gypsum based product |
Publications (2)
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CN104144895A true CN104144895A (en) | 2014-11-12 |
CN104144895B CN104144895B (en) | 2017-04-12 |
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CN201280069286.8A Active CN104144895B (en) | 2011-12-15 | 2012-12-13 | The method of the product of formation based on gypsum |
Country Status (20)
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US (1) | US9242870B2 (en) |
EP (2) | EP3599227B1 (en) |
JP (1) | JP6158211B2 (en) |
KR (1) | KR101953649B1 (en) |
CN (1) | CN104144895B (en) |
AU (1) | AU2012351635B2 (en) |
BR (1) | BR112014014564B1 (en) |
CA (1) | CA2860907C (en) |
DK (1) | DK2791074T3 (en) |
ES (2) | ES2768087T3 (en) |
GB (1) | GB2497574B (en) |
HK (1) | HK1199241A1 (en) |
HU (2) | HUE047598T2 (en) |
IN (1) | IN2014KN01463A (en) |
MY (1) | MY164602A (en) |
PL (2) | PL3599227T3 (en) |
RU (1) | RU2621238C2 (en) |
SG (1) | SG11201404052YA (en) |
WO (1) | WO2013087754A1 (en) |
ZA (1) | ZA201405134B (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
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EP2163532A1 (en) * | 2008-09-11 | 2010-03-17 | Claudius Peters Technologies GmbH | Method and device for manufacturing stone plaster |
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2011
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GB2213810A (en) * | 1988-01-14 | 1989-08-23 | Rwk Rhein Westfael Kalkwerke | Calcium-sulphate |
DE3927927A1 (en) * | 1989-08-24 | 1991-02-28 | Rwk Rhein Westfael Kalkwerke | Fibre-reinforced gypsum article prodn. e.g. for fibre board - by moulding autoclave-treated slurry of di:hydrate and fibres |
EP0572781A1 (en) * | 1992-05-30 | 1993-12-08 | Heidelberger Zement AG | Process for the preparation of alpha-hemihydrate from calcium sulphate dihydrate in a reactor |
CN102171156A (en) * | 2008-09-11 | 2011-08-31 | 克劳迪亚斯·彼得斯工程有限责任公司 | Method and system for the production of hard plaster |
CN102092974A (en) * | 2010-12-08 | 2011-06-15 | 太原理工大学 | Method and device for producing calcined gypsum slurry by hot press method |
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